Wiring board and method of manufacturing wiring board

ABSTRACT

A method of manufacturing a wiring board including forming a base substrate, forming a first insulation layer on a first surface of the base substrate and a second insulating layer on a second surface of the substrate opposing the first surface, forming an IVH (Interstitial Via Hole) that penetrates the base substrate, and cutting the first insulating layer in a first area and cutting the second insulating layer in a second area offset from said first area to form a first substrate laminated to a second substrate with the base layer interposed therebetween, the second substrate having a smaller mounting area than that of the first substrate such that the first substrate extends beyond an edge of the second substrate.

RELATED APPLICATION

This application is a divisional of and claims the benefit of priorityunder 35 U.S.C. §120 from U.S. Ser. No. 12/050,771, filed Mar. 18, 2008,which claims the benefit of U.S. Provisional Application Ser. No.60/938,596, filed May 17, 2007. The contents of those applications areincorporated herein by reference in its entirety.

FIELD OF TECHNOLOGY

The present invention relates to a wiring board formed by combining atleast two boards each having a different mounting area, and a method ofmanufacturing such a wiring board.

DESCRIPTION OF RELATED ART

Japanese Unexamined Patent Publication H5-152693 discloses technology tosolve insufficient rigidity in a wiring board. The technology relates toa wiring board having a reinforced section formed by making an extendedportion of a flexible substrate, and folding the extended portion.

Further, technology to provide wiring structures with high flexibilityis described, for example, in WO 05/029934. This publication discloses aprinted wiring board having a first substrate with a second substratelaminated on the first substrate, where the contour of the secondsubstrate is different from the contour of the first substrate. Theentire content of each of H5-152693 and WO 05/029934 is incorporatedherein by reference.

SUMMARY OF THE INVENTION

According to one embodiment, a wiring board includes a first substrate,a second substrate having a smaller mounting area than that of the firstsubstrate, and a base substrate laminated between the first substrateand the second substrate such that the first substrate extends beyond anedge of the second substrate. An IVH (Interstitial Via Hole) penetratesthe base substrate.

According to another embodiment, a method of manufacturing a wiringboard includes forming a first insulation layer on a first surface ofthe base substrate and a second insulating layer on a second surface ofthe substrate opposing the first surface, and forming an IVH(Interstitial Via Hole) that penetrates the base substrate. Alsoincluded is cutting the first insulating layer in a first area andcutting the second insulating layer in a second area offset from saidfirst area to form a first substrate laminated to a second substratewith the base layer interposed there between. The second substrate has asmaller mounting area than that of the first substrate such that thefirst substrate extends beyond an edge of the second substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1A is a side view illustrating a wiring board according to anembodiment of the present invention.

FIG. 1B is a plan view illustrating a wiring board according to anembodiment of the present invention.

FIG. 2 is a cross-sectional view illustrating a wiring board accordingto an embodiment of the present invention.

FIG. 3 is a cross-sectional view illustrating a wiring board accordingto an embodiment of the present invention.

FIG. 4 is a cross-sectional view illustrating a wiring board accordingto an embodiment of the present invention.

FIG. 5 is a cross-sectional view illustrating a wiring board accordingto an embodiment of the present invention.

FIG. 6 is a cross-sectional view illustrating a wiring board accordingto an embodiment of the present invention.

FIG. 7A is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7B is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7C is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7D is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7E is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7F is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7G is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7H is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7I is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7J is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7K is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7L is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7M is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7N is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7O is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7P is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7Q is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7R is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7S is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7T is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7U is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 7V is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 8 is a cross-sectional view of a wiring board according to anembodiment of the present invention.

FIG. 9A is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 9B is an illustration to describe a manufacturing step of a wiringboard according to an embodiment of the present invention.

FIG. 10 is a cross-sectional view of a wiring board according to anembodiment of the present invention.

FIG. 11 is a cross-sectional view of a wiring board according to anembodiment of the present invention.

FIG. 12 is a cross-sectional view of a wiring board according to anembodiment of the present invention.

DETAILED DESCRIPTION

In the following, an embodiment of a wiring board according to aspecific example of the present invention is described with reference tothe drawings.

As shown in FIG. 1A, wiring board 19 according to a specific example ofthe present invention has a different thickness on one edge from that onthe other edge. The number of layers in the section having a differentthickness (thicker section) differs from the number of layers in thethinner section. Namely, wiring board 19 has thick multi-layer section13 and a relatively thin fewer-layer section 14. Multi-layer section 13is formed by laminating two layers; first substrate 1 and secondsubstrate 2. Fewer-layer section 14 has first substrate 1 which isextended from multi-layer section 13. Thus, as used herein, the term“multi-layer section” means 2 or more layers or boards, while the term“fewer layer section” means one or more layers or boards.

As shown in FIGS. 1A and 1B, first substrate 1 and second substrate 2have the same width and different lengths, and one end of firstsubstrate 1 and one end of second substrate 2 are aligned. Firstsubstrate 1 and second substrate 2 are each made of non-pliable basematerial such as epoxy resin.

On the surfaces (mounting surfaces) of first substrate 1 and secondsubstrate 2, connecting pads to connect electronic components areformed; on the surfaces (mounting surfaces) and inner surfaces of firstsubstrate 1 and second substrate 2, wiring patterns to structureelectrical circuits are formed.

On the mounting surfaces of first substrate 1 and second substrate 2,electronic components 7, 8 are arranged and connected to connecting padsaccording to their requirements. Electronic components 7, 8 areconnected with each other through connecting pads and wiring patterns.

Wiring board 19 is placed, for example, in the casing of a cell phonedevice. In such a circumstance, electronic component 7 placed infewer-layer section 14 is structured, for example, with the keypad of akeyboard; and electronic component 8 placed in multi-layer section 13 isstructured with an electronic chip, IC module, functional components andothers. Also, in the step portion formed by multi-layer section 13 andfewer-layer section 14, for example, a thin-type battery is placed.

Next, a detailed structure of wiring board 19 having the above overallstructure is described in reference to FIG. 2. As illustrated, firstsubstrate 1 and second substrate 2 are laminated by sandwiching basesubstrate 3 between them. One end (the left end as illustrated in thedrawing) of base substrate 3 is made to be flush with first substrate 1and second substrate 2. Base substrate 3 is made of a highly rigidmaterial such as glass epoxy resin. Base substrate 3 is made 50-100 μm,preferably about 100 μm.

Base substrate 3 is formed to be shorter than second substrate 2, andbetween first substrate 1 and second substrate 2, groove (hereinafterreferred to as “interlayer groove portion”) 11 is formed. Interlayergroove portion 11 is an aperture. The groove may be filled with elasticmaterial such as silicon gel and silicon oil or viscous material orothers. When wiring board 19 receives an impact from being dropped, thegroove aperture or silicon gel or silicon oil that is filled in theinterior portion of the groove cushions the impact as a shock-absorbinglayer. Therefore, by being structured as such, tolerance to impact frombeing dropped may be improved.

First substrate 1 has a structure of laminated multiple insulationlayers (1 a, 1 b, 1 c). Each insulation layer is made of epoxy resin orthe like with a thickness approximately 10 μm-60 μm. On the uppersurface of insulation layer (1 a), between epoxy-resin layers (1 a) and(1 b), between insulation layers (1 b) and (1 c) and on the lowersurface of insulation layer (1 c), wiring patterns (111 a, 111 b, 111 c,111 d) are each formed. Each wiring pattern (111 a, 111 b, 111 c, 111 d)electrically connects required portions inside the circuit substrate.

Second substrate 2 also has a structure of laminated multiple insulationlayers (2 a, 2 b, 2 c) made of epoxy resin or the like with a thicknessof approximately 10 μm-60 μm. On the lower surface of insulation layer(2 a), between epoxy-resin layers (2 a) and (2 b), between insulationlayers (2 b) and (2 c) and on the upper surface of insulation layer (2c), wiring patterns (211 a, 211 b, 211 c, 211 d) are each formed. Eachwiring pattern (211 a, 211 b, 211 c, 211 d) electrically connectsrequired portions inside the circuit substrate.

On the exposed portion of the lower surface of first substrate 1 and theexposed portion of the upper surface of the second substrate, adhesionprevention layers 12 are formed as a protective insulation layer. At thestep portion created when laminating first substrate 1 and secondsubstrate 2, conductive pattern (111 d) is formed. Also, to the right ofconductive pattern (111 d) formed at the step portion, anotherconductive pattern (111 d) is formed.

Keypad 7 is placed on the conductive pattern formed on the surface offewer-layer section 14. Further, using solder 9, electronic chip 8 isanchored and connected to wiring patterns and built-up via 4 throughconnecting pads 10. For solder 9, Sn/Ag/Cu may be used.

Moreover, through-hole 63 is formed, penetrating base substrate 3 andconnecting wiring pattern (111 b) of first substrate 1 to wiring pattern(211 c) of second substrate 2. The inner surface of through-hole 63 isplated to electrically connect wiring patterns. The area enveloped byplated through-hole 63 may be filled with resin such as epoxy resin.

In first substrate 1 and second substrate 2, multiple built-up vias 4are formed. Built-up vias 4 are structured by stacking vias 44 formed ineach insulation layer (1 a-1 c, 2 a-2 c). Built-up vias 4 connectrequired portions of wiring patterns (111 a-111 d) and also connectrequired portions of wiring patterns (211 a-211 d). On the inner surfaceof each via 44 forming built-up via 4, a conductive layer made ofplated-copper or the like is formed. Thus, as used herein, the term viarefers to an opening formed in a substrate such as the insulating layer.As shown in FIG. 3, the interior portion of each via 44 is filled withconductor such as copper. However, as shown in FIG. 4, the interiorportion of via 44 (in the lower right portion of the drawing) may befilled with resin such as epoxy resin.

Wiring board 19 having the above structure, for example, transmitsoperational signals from keypad 7 to an IC chip through built-up vias 4,wiring patterns (111 a-111 d) and through-hole 63, and the signals arethen processed at the IC chip. By doing so, varieties of signalprocessing may be conducted.

Also, as described above, wiring board 19 is structured with multi-layersection 13 and fewer-layer section 14 and has a step portion. And at thelower portion of fewer-layer section 14, a large-volume component suchas a cell-phone battery may be placed.

Base substrate 3 is made of highly rigid material such as glass-epoxyresin. Multi-layer section 13, because of base substrate 3 placed there,is highly rigid compared with fewer-layer section 14. On the other hand,fewer-layer section 14 is relatively flexible compared with multi-layersection 13. Thus, it is possible to place electronic components oneither section 13 or 14 according to the reliability level they require.

Also, for example, when the electronic device is dropped and an impactor the like is exerted on wiring board 19, due to the relativeflexibility of fewer-layer section 14 compared with multi-layer section13, fewer-layer section 14 vibrates as shown by arrow 37 in FIG. 5.Since portions of fewer-layer section 14 vibrate, the impact from beingdropped or the like is converted to vibration movement energy, and theimpact is absorbed accordingly. As a result, the wiring connecting theelectronic components mounted on wiring board 19 may seldom rupture.

Also, built-up via 4 is structured as a stacked via made by laminatingmultiple vias 44. By making such a stacked interlayer connectionstructure, the wiring length may be shortened, and thus preferable formounting electronic components requiring large amount of electricity.

Moreover, built-up via 4 has a certain degree of mobility. Therefore,for example, when the electronic device is dropped and an impact isexerted on wiring board 19, the impact may be absorbed at built-up via 4through the movement of built-up via 4 as shown by arrows 38, 39 in FIG.6. As a result, the wiring connecting the electronic components mountedon wiring board 19 may seldom rupture.

In addition, if solid material or the like is filled in interlayergroove portion 11, when the impact of being dropped or the like isexerted on the wiring board, interlayer groove portion 11 cushions theimpact as a shock-absorbing layer. Accordingly, when interlayer grooveportion 11 is formed, by improving tolerance to impact from beingdropped, the wiring connecting the electronic components mounted on thewiring board may seldom rupture.

Also, in certain circumstances, two wiring boards of the presentinvention may be combined and sold in such a way that each fewer-layersection 14 is closely placed to provide compact shipment of the boardsas will be further discussed with respect to FIG. 7V below. Here, if awiring pattern is formed at the step portion created when firstsubstrate 1 and second substrate 2 are laminated, in the circumstancewhen a user such as a device manufacturer uses the combined wiringboards of the present invention separately, warping of the wiring boardsmay be prevented. Namely, multi-layer section 13, because of basesubstrate 3 deposited there, is rigid compared with fewer-layer section14. Thus, when a user separates the combined wiring boards of thepresent invention, warping does not occur at multi-layer section 13. Onthe other hand, fewer-layer section 14 is flexible compared withmulti-layer section 13. Thus, when a user separates the combined wiringboards of the present invention, warping could possibly occur atfewer-layer section 14, especially at the step portion of fewer-layersection 14 created when first substrate 1 and second substrate 2 arelaminated. However, if a wiring pattern is formed at the step portion,even when a user or the like uses the combined wiring boards of thepresent invention separately, warping may be prevented.

In the following, a method of manufacturing wiring board 19 according tothe present invention is described.

First, as shown in FIG. 7A, dummy core 52 which later forms adhesionprevention layer 12 is prepared. Dummy core 52 is, for example, formedwith a C-stage epoxy resin. On dummy core 52, copper foil 51 isdeposited.

Next, as shown in FIG. 7B, by patterning copper foil 51, conductivepattern (111 d) is formed at a predetermined position.

Then, as shown by arrows in FIG. 7C, dummy core 52 is cut by a laser orthe like (represented by the arrows in FIG. 7C) to adjust its length toa length preferred for use in wiring board 19. As seen in FIG. 7C, thedummy core 52 is cut into dummy cores 52 a and 52 b, which will be usedto form separate wiring boards as described below.

In addition, as shown in FIG. 7D, core 55, which later functions as basesubstrate 3, is prepared. Core 55 is made, for example, of highly rigidmaterial such as glass-epoxy resin. On both surfaces of core 55, copperfoil 54 is deposited.

Next, as shown in FIG. 7E, by patterning copper foil 54, conductivepatterns (111 d, 211 a) are formed to structure wiring patterns.

Next, as shown by an arrow in FIG. 7F, in core 55 using a laser or thelike, a hole to insert dummy core 52 is formed.

Next, as shown in FIG. 7G, cut-out dummy cores (52 a, 52 b) are placedin such a way that conductive pattern (111 d) are laminated facinginward. Then, laminated dummy cores (52 a, 52 b) and cut core 55 arehorizontally connected. Further, on the top and bottom of dummy cores(52 a, 52 b) and core 55, prepreg (62 a, 62 b) are laminated. Forprepreg (62 a, 62 b), low-flow prepreg impregnated with low-flow epoxyresin is preferred. Then, on the surfaces of prepreg (62 a, 62 b),copper foils (61 a, 61 b) are deposited.

Next, as shown in FIG. 7H, the laminated layers shown in FIG. 7G arepressure-pressed as represented by the arrows in FIG. 7H. Pressurepressing is, for example, conducted by hydraulic power using hydraulicpressing equipment under conditions calling for temperature of 200° C.,pressure of 40 kgf and pressing time of three (3) hours. By doing so,resin leaks from the prepreg, and the prepreg (62 a, 62 b) and corematerial 55 will be integrated. At this time, since dummy core 52 ismade of a C-stage epoxy resin, the materials in dummy cores (52 a, 52 b)are not integrated with each other. For pressure pressing, vacuumpressing may be employed instead of hydraulic pressing. By vacuumpressing, bubbles may be prevented from being mixed into the resin thatstructures the insulation layers. Vacuum pressing is conducted, forexample, for an hour. Peak heating temperature is set, for example, at175° C.; and vacuum-pressing pressure is set, for example, at 3.90×10⁶[Pa].

Next, in the laminated layer shown in FIG. 7H, holes are bored using adrill. By doing so, as shown in FIG. 7I, through-holes 63 are formed.Further, plating 63 a may be formed on an interior surface of thethrough-hole 63.

When forming an IVH (Interstitial Via Hole), a CO₂ laser beam isprovided from CO₂ laser processing equipment to bore a hole ininsulation layers. Then, at a via-forming step described later referringto FIG. 7M, vias may be stacked at both ends of the IVH. The term IVHmeans a conductive structure which is formed by a hole that penetrates abase substrate or insulating layers, for example, but does not penetratethrough a multilayered printed board itself, and plating the hole toelectrically connect two or more conductive layers. An IVH occupies aspace required for a connection, and includes, for example, a blind viahole structure formed in an outer layer of a multilayered printed wiringboard and a buried via hole structure formed in an inner layer of themultilayered printed wiring board.

Next, as shown in FIG. 7J, by removing the unnecessary portions ofcopper foil 61, an inner-layer pattern 63 b is formed.

Next, as shown in FIG. 7K, epoxy resin (72 a, 72 b) is further laminatedto form inner layers. On surfaces of epoxy resin (72 a, 72 b) copperfoil (71 a, 71 b) is deposited.

Next, as shown in FIG. 7L, after the lamination in reference to FIG. 7K,pressure pressing is conducted as represented by the arrows in FIG. 7L.Pressure pressing may be conducted, for example, by hydraulic powerusing hydraulic pressing equipment, or may be conducted by vacuumpressing. Portions of epoxy resin 72 are filled in through-holes 63.

Next, as shown in FIG. 7M, vias 44 are formed. Namely, in epoxy resin(72 a, 72 b) made of insulation resin, via-hole openings are formed.Those openings may be formed by a laser beam. And, to remove resinresidue remaining on the side and bottom surfaces of the openings formedby beaming a laser, a desmear treatment is preferably carried out. Thedesmear process is performed using an oxygen plasma discharge treatment,a corona discharge treatment, an ultra-violet laser treatment or anexima laser treatment. In the openings formed by the laser beam, forexample, conductive material is filled to form filled-via holes. Forconductive material, a conductive paste or metal plating formed byelectrolytic plating process is preferred. For example, vias 44 arefilled with conductor such as copper plating. To reduce themanufacturing cost and improve productivity by simplifying thefilled-via forming step, filling with a conductive paste is preferred.For example, a conductive paste (such as thermo-set resin containingconductive particles) may be printed by screen-printing, filled in vias44 and set. By filling the inner portion of vias 44 with the sameconductive paste material, connection reliability when thermo-stress isexerted on vias 44 may be improved. On the other hand, regardingconnection reliability, metal plating formed by an electrolytic platingprocess is preferred. Especially, electrolytic copper plating ispreferred.

Next, as shown in FIG. 7N, by removing the unnecessary portions ofcopper foils 71, inner-layer patterns are formed.

Next, as shown in FIG. 7O, after inner layers and vias are furtherformed, epoxy resin (81 a, 81 b) is laminated to form outer layers. Onsurfaces of epoxy resin (81 a, 81 b), copper foil (82 a, 82 b) isdeposited. Here, a copper foil sheet with resin (Resin Copper Film: RCF)may be deposited and pressed.

Next, as shown in FIG. 7P, in the RCF, vias 81 c are formed. Further,using copper plating or the like, the interior portions of the vias arefilled with conductor 81 d. Also, according to requirements, bypatterning the surface copper foil, a conductive pattern is formed.Thus, as shown in FIG. 7Q, by removing the unnecessary portions ofcopper foils (82 a, 82 b), outer-layer patterns are formed.

Next, as shown in FIG. 7R, solder-resists 83 are formed. Here, thesolder resist indicates heat-resistant coating material, which is usedwhen applying solder to cover the portions where the solder is to bekept from adhering. For solder-resist varieties, photo-setting typesolder resist and thermo-setting type solder resist may be used. For acoating method, a screen-printing method or curtain-coating method maybe used.

Next, as shown in FIG. 7S, to protect outer-layer patterns, gold plating91 is performed by chemical plating. Other than chemical plating,methods such as fusion plating and electrical plating may be used.Moreover, materials other than gold plating, such as alloy plating forexample may be used.

Next, as shown by arrows 40 in FIG. 7T, laser beams from laserprocessing equipment, for example CO₂ laser, are irradiated usingconductive patterns (111 d) as a stopper to cut insulation layers andthe copper foil sheet with resin (RCF). Here, the thickness ofconductive patterns (111 d) is preferred to be made approximately 5-10μm: if too thin, laser beams penetrate the pattern; and if too thick,conductive patterns with a fine line width are difficult to form.

Meanwhile, by laser cutting as shown in FIG. 7T, interlayer grooveportions (11 a, 11 b) are also formed. Namely, by laser cutting, usingadhesion prevention layer 12 formed in first substrate 1 and adhesionprevention layer (12 a, 12 b) formed in second substrate 2 as grooveside-walls, and one surface of base substrate 3 as groove bottom,interlayer groove portions (11 a, 11 b) are formed.

Lastly, as shown in FIG. 7U, electronic components 92 are mounted.Electronic components 92 are an electronic chip 8 and keypad 7. Further,in interlayer groove portions (11 a, 11 b), elastic material, viscousmaterial or the like may be filled as depicted by the darkened portionshown in the interlayer groove portions in FIG. 7U.

Further, as shown in FIG. 7V, wiring board (19A) and wiring board (19B)are used separately. In such a circumstance, since adhesion preventionlayers (12 a, 12 b) are formed, wiring board (19A) and wiring board(19B) may be separated by a simple process to be used separately.Regarding a wiring board according to the present invention, when anelectronic device such as a cell phone receives an impact from beingdropped or the like, connection breakage of electronic components or thelike mounted in the wiring board may be prevented. Also, when beingshipped to a user, the wiring board may be handled compactly, and whenbeing used by the user, the combined wiring boards may be separatedeasily.

As shown in FIG. 8, in the Second Embodiment, at the portion whereadhesion prevention layer 12 is made flush with the edge of secondsubstrate 2, opening 5 is formed. Also in this embodiment wiringpatterns 111 d serving as stop layers are faced outward as will befurther discussed below. The rest of the structure is the same as in theFirst Embodiment. Under opening 5, part of wiring pattern (111 d) ispositioned. Inside the groove formed with opening 5 and wiring pattern(111 d) placed underneath is an aperture. The groove may be filled withelastic material such as silicon gel or silicon oil or viscous material.When wiring board 19 receives an impact from being dropped, the apertureinside the groove or silicon gel or silicon oil filled in the groovecushions the impact as a shock-absorbing layer. Therefore, by makingsuch a structure, tolerance to impact from being dropped may beimproved.

Also, if solid material or the like is filled in opening 5, the filledsolid material or the like may play a role in decreasing warping at thejuncture of multi-layer section 13 and fewer-layer section 14 where thenumber of layers is reduced. Accordingly, at the juncture of multi-layersection 13 and fewer-layer section 14, cracks may be prevented.Furthermore, if opening 5 is filled with, for example, solid materialsuch as resin, the filled solid material plays a role in protectingconductive pattern (111 d) mounted on first substrate 1. Therefore,tolerance to corrosion of conductive pattern (111 d) may be improved.

The method of manufacturing a wiring board according to the SecondEmbodiment is the same as the method of manufacturing a wiring boardaccording to the First Embodiment in reference to FIGS. 7A-7F. However,FIG. 9A shows how the method of the second embodiment deviates from FIG.7G of the first embodiment. As shown in FIG. 9A, cut-out dummy cores (52a, 52 b) are placed in a way so that conductive pattern (111 d) arelaminated facing outward (rather than inward as shown in FIG. 7G). Themethod of the second embodiment then progresses in the same way as shownin FIGS. 7H-7T of the first embodiment. However, FIG. 9B shows how themethod of the second embodiment deviates from FIG. 7U of the firstembodiment. As shown in FIG. 9B, opening 5 is filled with viscousmaterial such as silicon oil, for example. However, other materials maybe provided in holes 5.

In the First Embodiment, base substrate 3 was made of glass-epoxy resin.However, as shown in FIG. 10, in the Third Embodiment, base substrate 3is made containing base material of resin-impregnated inorganic fiber.By being structured as such, since base substrate 3 contains basematerial of resin-impregnated inorganic fiber, tolerance to warping maybe improved.

The base material made of resin-impregnated inorganic fiber is formed bysetting a prepreg. Prepreg is made by impregnating glass-cloth ofinorganic fiber with epoxy resin, then preliminarily thermosetting theresin to advance the level of setting. The resin used to form theprepreg is preferred to have low-flow characteristics; however, thosehaving regular flow characteristics may be used as well. Also, theprepreg may be formed by reducing the amount of epoxy-resin impregnatedin the glass-cloth of inorganic fiber.

As for the inorganic fiber, it is not limited to glass-cloth, but forexample, alumina fiber, carbon fiber (carbon fiber), silicon carbidefiber or silicon nitride fiber may be used. The method of manufacturinga wiring board according to the Third Embodiment is the same as that ofFIGS. 7A-7U of the first embodiment except that, referring to FIG. 7D,as the material to form core 55, base material of resin-impregnatedinorganic fiber is used. The rest of the process is the same as themethod of manufacturing a wiring board according to the FirstEmbodiment.

In the above-described First Embodiment, base substrate 3 was made ofglass-epoxy resin. First substrate 1 and second substrate 2 are made ofepoxy resin. However, the combination of material for base substrate 3and material for first substrate 1 and second substrate 2 is not limitedto the above. As shown in FIG. 11, in the Fourth Embodiment, basesubstrate 3 is made containing base material of resin-impregnatedinorganic fiber; and first substrate 1 and second substrate 2 are madecontaining inorganic filler composite resin. By structuring such, sincebase substrate 3 contains base material of resin-impregnated inorganicfiber, tolerance to warping may be improved. Accordingly, when anelectronic device such as a cell phone receives an impact from beingdropped or the like, the wiring connecting electronic components mountedin the wiring board may seldom rupture.

An inorganic filler composite resin may be made by combining silicafiller or glass filler with epoxy resin. In addition to epoxy resin, orother than epoxy resin, polyimide, polycarbonate,polybutylene-telephtarate or polyacrylate may be used.

For silica filler, fused silica (SiO₂) or crystalline silica (SiO₂) maybe used. Also, for glass filler, aluminum oxide (Al₂O₃), magnesium oxide(MgO), or boron nitride (BN), aluminum nitride (AlN) may be used.Furthermore, for inorganic filler, it is not limited to silica filler orglass filler, but antimony trioxide, antimony pentaxide or magnesiumhydroxide may be used.

The method of manufacturing a wiring board according to the FourthEmbodiment, referring to FIG. 7D, as the material to form core 55, abase material of resin-impregnated inorganic fiber is used. In addition,referring to FIGS. 7G, 7K and 7O, for the resin to be laminated,inorganic filler composite resin is used. The rest is the same as themethod of manufacturing a wiring board according to the FirstEmbodiment.

In the above-described First Embodiment, base substrate 3 is made ofglass-epoxy resin. And first substrate 1 and second substrate 2 weremade of epoxy resin. However, the combination of material for basesubstrate 3 and material for first substrate 1 and second substrate 2 isnot limited to the above embodiment. As shown in FIG. 12, in the FifthEmbodiment, base substrate 3 is made containing inorganic fillercomposite resin; and first substrate 1 and second substrate 2 are madecontaining a base material of resin-impregnated inorganic fiber. By suchstructuring, since at least either first substrate 1 or second substrate2 is reinforced with inorganic fiber, tolerance to warping may beimproved. Accordingly, when an electronic device such as a cell phonereceives an impact from being dropped or the like, the wiring connectingelectronic components mounted in the wiring board may seldom rupture.

Above-described inorganic material such as inorganic fiber or inorganicfiller has small thermo-expansion rates and low coefficient ofelasticity compared with resin of an organic material. Therefore, wheninorganic material such as inorganic fiber or inorganic filler iscombined, alignment gaps between connecting lands may be reduced.

In the method of manufacturing a wiring board according to the FifthEmbodiment, referring to FIG. 7D, as the material to form core 55,inorganic filler composite resin is used. In addition, referring toFIGS. 7G, 7K and 7O, as the material to be laminated, base material ofresin-impregnated inorganic fiber is used. The rest is the same as themethod of manufacturing a wiring board according to the FirstEmbodiment.

In a wiring board according to the First Embodiment of the presentinvention, first substrate 1 and second substrate 2 are in a stratumstructure having a rectangular outline. However, they are not limited tosuch, but may be in a stratum structure having a circular, hexagonal, oroctagonal outline.

Also, in the First Embodiment, first substrate 1 and second substrate 2are made of epoxy resin. However, first substrate 1 and second substrate2 are not limited to such, but may be made of polyimide, polycarbonate,polybutylene-telephtarate or polyacrylate. In addition, if firstsubstrate 1 and second substrate 2 are made of epoxy resin,naphthalene-type epoxy resin, dicyclo-penta-diene-type epoxy resin,biphenyle-type epoxy resin or bisphenole-type epoxy resin may be used.

In the First Embodiment, as solder 9, Sn/Ag/Cu was used. However, solder9 is not limited to such; solder containing antimony, tin, lead, indiumor copper may be used. Also, eutectic crystal metals such as Sn/Sb,Sn/Ag, Sn/Pb or Sb/Cu may be used as well. Among such eutectic crystalmetals, to avoid having a bad influence on the substrates, using thosehaving relatively low melting temperatures, 250° C. or lower, ispreferred.

In the First Embodiment, in interlayer groove portion 11, silicon gel ofviscous silicon is filled. However, filling interlayer groove portion 11is not limited to such, and solid material may also be used. As solidmaterial to be filled in interlayer groove portion 11, high-polymerrubber is preferred as a solid material having viscosity and elasticity.Specifically, butyl-rubber, isoprene rubber, butadiene rubber,styrene-butadiene rubber or ethylene-propylene rubber may be used.Moreover, interlayer groove portion 11 may be filled with a gas. As thegas to be filled in interlayer groove portion 11, a rare gas such asargon, or nitrogen or oxygen may be used.

In the Second Embodiment, in opening 5, silicon gel of viscous siliconis filled. However, the material to be filled in opening 5 is notlimited to such, but solid material may be filled in opening 5. As solidmaterial to be filled in opening 5, high-polymer rubber as solidmaterial having viscosity and elasticity is preferred. Specifically,butyl-rubber, isoprene rubber, butadiene rubber, styrene-butadienerubber or ethylene-propylene rubber may be used. As the material to befilled in opening 5, a liquid or solid material is preferred, but a gasmay also be filled. In such a case, as the gas to be filled in opening5, a rare gas such as argon, or nitrogen or oxygen may be used.

In addition, first substrate 1 may not need to be formed single-layered,but may be formed multi-layered. Namely, first substrate 1 may bestructured with a lower-layer insulation layer and an upper-layerinsulation layer. Here, a lower-layer insulation layer indicates theinsulation layer formed close to base substrate 3; and an upper-layerinsulation layer indicates an insulation layer formed on the outersurface of the wiring board. Furthermore, first substrate 1 may bestructured with a lower-layer insulation layer, an upper-layerinsulation layer and an intermediate insulation layer placed in between.The intermediate insulation layer may be made multi-layered. In theFirst Embodiment, the lower-layer insulation layer corresponds toepoxy-resin layer (1 c), the intermediate insulation layer correspondsto epoxy-resin layer (1 b) and the upper-layer insulation layercorresponds to epoxy-resin layer (1 a).

Also, the second substrate may not need to be formed single layered, butmay be formed multi-layered. And second substrate 2 may also bestructured with a lower-layer insulation layer and an upper-layerinsulation layer. Furthermore, second substrate 2 may be structured witha lower-layer insulation layer, an upper-layer insulation layer and anintermediate insulation layer placed in between. In the FirstEmbodiment, the lower-layer insulation layer corresponds to epoxy-resinlayer (2 a), the intermediate insulation layer corresponds toepoxy-resin layer (2 b) and the upper-layer insulation layer correspondsto epoxy-resin layer (2 c). On top of the upper-layer insulation layerand lower-layer insulation layer, conductive patterns are formed. And,those conductive patterns may be connected with each other through vias44. The present invention may be employed in a wiring board which canmount electronic components, specifically, in a wiring board which canmount electronic components for a compact electronic device.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, theinvention may be practiced otherwise than as specifically describedherein.

1. A method of manufacturing a wiring board comprising: forming a basesubstrate; forming a first insulation layer on a first surface of thebase substrate and a second insulating layer on a second surface of thesubstrate opposing the first surface; forming an IVH (Interstitial ViaHole) that penetrates the base substrate; and cutting the firstinsulating layer in a first area and cutting the second insulating layerin a second area offset from said first area to form a first substratelaminated to a second substrate with the base layer interposedtherebetween, the second substrate having a smaller mounting area thanthat of the first substrate such that the first substrate extends beyondan edge of the second substrate.
 2. The method of manufacturing a wiringboard according to claim 1, further comprising: forming an interlayergroove portion between the first substrate and the second substrate; andfilling the interlayer groove portion with at least one of a gas, liquidor solid material.
 3. The method of manufacturing a wiring boardaccording to claim 1, further comprising forming a warping preventionportion at a step portion created when the first substrate and thesecond substrate are laminated with the base substrate interposedtherebetween.
 4. The method of manufacturing a wiring board according toclaim 1, further comprising: forming an opening at a step portioncreated when the first substrate and the second substrate are laminatedwith the base substrate interposed therebetween; and filling the openingwith at least one of a gas, liquid or solid material.
 5. The method ofmanufacturing a wiring board according to claim 1, wherein: the basesubstrate comprises a resin-impregnated inorganic fiber, the firstsubstrate comprises at least one of an inorganic filler composite resinor pliable resin, and the second substrate comprises at least eitherinorganic filler composite resin or pliable resin.
 6. The method ofmanufacturing a wiring board according to claim 5, wherein the inorganicfiber comprises glass cloth.
 7. The method of manufacturing a wiringboard according to claim 5, wherein at least one of the first substrateor the second substrate comprises the inorganic filler which comprisesat least one of silica filler or glass filler.
 8. The method ofmanufacturing a wiring board according to claim 1, wherein: the basesubstrate comprises inorganic filler composite resin, and at least oneof the first substrate or the second substrate comprisesresin-impregnated inorganic fiber.
 9. The method of manufacturing awiring board according to claim 8, wherein the inorganic fiber comprisesglass cloth.
 10. The method of manufacturing a wiring board according toclaim 8, wherein the inorganic filler comprises at least one of silicafiller or glass filler.
 11. The method of manufacturing a wiring boardaccording to claim 1, further comprising: forming a conductive patternon the first substrate; forming a conductive pattern on the secondsubstrate; and connecting the conductive pattern on the first substrateand the conductive pattern on the second substrate by way of thethrough-hole.
 12. The method of manufacturing a wiring board accordingto claim 1, further comprising: forming stacked vias in each of theinsulation layers; forming a conductive layer on an inner surface of atleast one of the stacked vias by plating; and filling the at least onestacked via with metal.
 13. The method of manufacturing a wiring boardaccording to claim 1, further comprising: forming stacked vias in eachof the insulation layers; forming a conductive layer on an inner surfaceof at least one of the stacked vias by plating; and filling the at leastone stacked via with resin.
 14. The method of manufacturing a wiringboard according to claim 1, wherein: the first substrate comprises afirst lower-layer insulation layer and a first upper-layer insulationlayer, and the second substrate comprises a second lower-layerinsulation layer and a second upper-layer insulation layer.
 15. Themethod of manufacturing a wiring board according to claim 14, furthercomprising: forming a conductive pattern on each of the upper-layerinsulation layers; forming a conductive pattern on each of thelower-layer insulation layers; and connecting each conductive pattern onthe upper-layer insulation layers to a respective conductive pattern onthe lower-layer insulation layers through stacked vias.